Method and apparatus for cutting a web of material in a web winding machine and air lapping a cut end of the material about a winding core in the machine

ABSTRACT

A web of material continuously drawn off from a supply roll is wound in a web winding machine to a rolled diameter of a desired size and then severed by means of a vertically movable cutter to provide a trailing end and a free end. The finished roll and its trailing end are moved ahead into doffing position. A new roll is started by feeding a cylindrical shell or core into the winding position vacated by the finished roll. As the shell is located in this winding position, the free end of the cut web is wrapped around the shell in overlapping relationship and by means of specially devised air lapping apparatus combined with the vertically movable cutter. With the cutter mechanism in motion upwardly, the air lapping apparatus serves to provide travelling jets of air which are laterally directed against the rear driving roll and which start while below the uncut web, then travel upwardly just under the shell or core as a cut occurs so that the jets progressively follow the cut end of material and continuously force it into an arcuate wrap-around position which positively secures the free end and avoids bunching or irregular lapping.

ited States Patent 11 1 Straujups METHOD AND APPARATUS FOR CUTTING A WEB OF MATERIAL IN A WEB WINDING MACHINE AND AIR LAPPING A CUT END OF THE MATERIAL ABOUT A WINDING CORE IN THE MACHINE [75] Inventor: John E. Straujups, Lexington, Mass. [73] Assignee: Birch Brothers, Inc., Somerville,

[ Nov. 5, 1974 Primary Examiner-John W. Huckert Assistant Examiner-Edward J. McCarthy Attorney, Agent, or Firm-Munroe l-l. Hamilton [5 7 ABSTRACT A web of material continuously drawn off from a supply roll is wound in a web winding machine to a rolled diameter of a desired size and then severed by means of a vertically movable cutter to provide a trailing end and a free end. The finished roll and its trailing end are moved ahead into dofting position. A new roll is started by feeding a cylindrical shell or core into the winding position vacated by the finished roll. As the shell is located in this winding position, the free end of the cut web is wrapped around the shell in overlapping relationship and by means of specially devised air lapping apparatus combined with the vertically movable cutter. With the cutter mechanism in motion upwardly, the air'lapping apparatus serves to provide travelling jets of air which are laterally directed against the rear driving roll and which start while below the uncut web, then travel upwardly just under the shell or core as a cut occurs so that the jets progressively follow the cut end of material and continuously forceit into an arcuate wrap-around position which positively secures the free end and avoids bunching orirregular lapping.

5 Claims, 8 Drawing Figures SHEET 1 0f 4 PATENTED NOV 5 I974 PATENTEUNUV W Sam 4 3,845,914

METHGD AND APPARATUS FOR CUTTING A WEB F MATERIAL IN A WEB WINDING MACHINE AND AIR LAPPING A CUT END OF THE MATERIAL ABOUT A WINDING CORE IN THE MACHINE This invention is concerned with the field of web winding and relates particularly to web winding machines in which a, web of materials is continuously drawn off from a supply roll and wound to a roll diameter of a desired size in a web winding machine. At the point at which the wound roll diameter reaches a desired size, the web is cut and the finished roll is moved out of the machine. As is customary in most web winding machines, a new roll is simultaneously started by lapping a free cut end of the web over a hollow core or shell inserted in a winding position in the machine in place of the finished roll.

Various arrangements have been proposed in the art for cutting a web and lapping a cut end about a hollow core or shell. In U.S. Pat. No. 3,049,311 there is disclosed atypical form of web winding machine in which are provided lapping rolls which are pivotally arranged tomechanically engage a cut end of material and wrap it around a shell with the lapping rolls traveling around the shellin an arcuate path of travel. U.S. Pat. No. 2,537,588 utilizes metal fingers for mechanically lapping in conjunction with the application of stationary fluid jets. More recently the use of stationary air jets has been proposed as described in U.S. Pat. No. 3,592,403 and also in U.S. Pat. No. 3,556,424.

In allof these prior art devices, difficulty is experienced in one way or another. Conventional lapping devices may, in some instances, fail to handle a cut end properly or uniformly andthis can result in improper wrapping with bunching or wrinkling occurring. Conventional lapping devices involve several movable parts which must be maintained in properly adjusted relationship at some additional expense. There is also an objectionable delay in starting a new roll with conventional lapping devices. Still another troublesome problem arises in that these conventional lapping devices, either of the mechanical or air jet type, are not well adapted to handling a range of core diameters which are now being required in the web winding art. It should be understood that finished rolls of wound material may be received by customers and mounted on shaft members for unrolling. These shaft members may vary in diameter from one customer to another and because of this, the inner diametersof hollow cores utilized to fill orders may range from 1 inch all the way up to as much as 7 inches.

It is, therefore, a chief object of the present invention to improve web winding machines and to devise a more efficient, rapid and reliable lapping means for wrapping a cut end of a web of material around a hollow supporting shell or core to start building a roll of wound material in place of a roll which has been finished and removed from the machine.

Another specific object of the invention is to devise air lapping apparatus for use with a chain cutting mechanism of the class disclosed in U.S. Pat. No. 3,485,121 and also U.S. Pat. No. 3,199,393.

Still another object is to provide a combination of air jet lapping means with a vertically movable chain cutter in order that the air jet means may be progressively wrapped from a starting position below a newly inserted shell upwardly to points just under a portion of a web which is about to be cut.

Still another object of the invention is to devise a combination of web cutting means and air lapping apparatus in which the air jet mechanism is uniquely housed interiorly of the chain cutter means in a manner such that a wide range of core diameters may be accommodated and jets of air may be directed along points occurring below a newly inserted shell before a cut occurs and then progressively moved upwardly while cutting takes place.

With the foregoing objectives in mind, I have conceived of an improved web cutting and air lapping apparatus for a web winding machine in which a web of material is required to be cut off from a finished roll of material. The air lapping apparatus is combined interiorly of a chain cutter frame which supports dual chain cutters vertically movable to cut the web. The air lapping apparatus moves as an integral part of the chain cutter frame in suitably spaced relation below the chain cutters. The arrangement of parts provides for directing traveling jets of air along points below a rotatable core on which a new roll is to be started. The air jets are moved upwardly to impinge along points just under the core as a cut occurs with the result that further upward travel of the jets causes a cut end of the material to be constantly forced against the core surface and progressively wrapped around the core surface in a wrinkle-free and uniformly wrapped relationship. With the interiorly disposed arrangement of the air jet apparatus in the chain cutter frame, I am able to control the distance between the cutter chain and the line of air jets in a unique and desirable mannerand it becomes possible to operate with a wide range of core diameters with important savings in time and handling.

The nature of the invention and its other objects and novel features will be more fully understood and appreciated from the following description of a preferred embodiment of the invention selected for purposes of illustration and shown in the accompanying drawings, in which:

FIG. 1 is a side elevational view of a web winding machine with which is combined the chain cutter and air lapping apparatus of the invention;

FIG. 2 is a detail elevational view of, on a larger scale, the chain cutter and air lapping apparatus;

FIG. 3 is a cross section taken on the line 3-3 of FIG. 2;

FIG. 4 is a fragmentary elevational view of the winding machine indicating a web and cutter means in a position to be moved upwardly to make a cut;

FIG. 5 is a diagrammatic view illustrating a web and a cutter and air jet means raised into a cutting position and with the air jet means directing jets of air at points beneath the hollow core and below the web;

FIG. 6 is another diagrammatic view similar to FIG. 5 and illustrating the web severed by the cutter mechanism and the air jets being raised into a position to force a cut end of the web against the core;

FIG. 7 is a plan view of the cutter mechanism and portions of the air jet means;

FIG. 8 is a side elevational view of cutter means on a larger scale.

Referring more in detail to the structure shown in the drawings, numeral 2 denotes vertical side portions of a web winding machine of the type noted in U.S. Pat. No. 3,049,311 and which operates to draw off a web W from a supply roll not shown. Supported between the side frames 2 is a rear driving roll 4 and a forward driving roll 6 and respective power driven shafts 4a and 6a. Also supported between the side frame 2 for vertical displacement above the rolls 4 and 6 is a rotatable hollow winding core 8. As is cutomary in machines of this class, ends of the core 8 are received in vertically movable jaws as and 12. These jaws are slidably retained in rack and pinion guide parts as 14.

As winding starts with the core 8 turning on the roll 4, it will be understood that a roll R is built up to some predetermined diameter. At such a point, the finished roll is transferred into a doffing position being supported on rolls 6 and 7. A finished roll R1 is indicated in broken lines at the right hand side of FIG. 1. In thus moving from engagement with roll 4 onto rolls 6 and 7, the web of material W being drawn off from a conventional supply roll becomes extended away from the roll 4 to provide a horizontally disposed span of material which is required to be cut. Cutting is carried out'by vertically movable chain cutter means generally indicated by letter C. A shell feeding arm S is pivotally mounted at one side of the machine in a position to pcriodically receive a shell from a shell feeding magazine and to locate the shell in the jaws 10 and 12.

It is customary for movement of the shell feeding arm to be synchronized with shifting of the finished roll onto rolls 6 and 7 so that the shell 8 is positioned in the jaws l0 and 12 before the extended span of web W is cut.

FIG. 1 is intended to illustrate the above-described parts just after the shell 8 has been placed in the jaws I0 and 12 and the extended span of web W has been cut to define a trailing edge T and a free end F. FIG. 1 also illustrates the free end F having been wrapped around the shell 8 in accordance with the method of the invention and making use of the special air apparatus of the invention.

Considering in greater detail the chain cutter and air jet apparatus of the invention, attention is directed to FIGS. 2 to 8 inclusive. As shown therein, the chain cutter C includes a pair of endless chain cutters Cl and C2 mounted on shafts C3, C4, C9 and C10. The shafts C3 and C4 are provided with sprocket gears as C5, C6 driven by electric motor actuated sprocket chains C7 and C8. The chains are supported in depending housings l6 and 18, best shown in FIG. 2 secured at the underside of a frame body 20. The frame body includes bearing posts 17a and 1712, a pair of spaced apart side walls 200 and b through which are transversely received the chain shafts C3, C4, C9 and C10. The hearing posts 17a and 17b are designed to support the cutter apparatus when in a fully bottomed position. Secured at the under edge of the side walls 20a and 20b are a plurality of spaced blocks as 30, 32 (FIG. 3) solidly joined together by a tansversely disposed base plate 34, best shown in FIG. 3. At its underside, the base plate 34 is received on a retaining cap 36 fixed to a plunger 38 of a fluid pressure actuated member 40 which is preferably activated by compressed air. Arrow 42 indicates a compressed air supply for supplying air to the member 40 through a two-way solenoid valve 41.

In combination with the chain cutter parts above described I provide a movable air jet apparatus which is contained interiorly of the chain cutter frame sides and in predetermined spaced relationship below the undersides of the cutter chains in a manner such that when the cutter is in a fully bottomed position, air jets .I may be laterally directed against the roll 4 well below the core 8. These air jets J are produced by means of an air lapping tube 50 located between the frame portions 30 and 32 as shown in FIGS. 2 and 3. The air lapping tube 50 is formed along one side by a series of spaced air jet apertures 52 which are designed to register with bays or openings 54 defined in the cutter frame by the spaced blocks 30. Compressed air from supply source 42 is contained in a tank 44 and selectively released therefrom through a two-way solenoid valve 46 and a time-delay valve 48.

An important feature of this air lapping apparatus is the provision of air conduits 56 and 58 which are fitted into T-connections 60 and 62 connected into the underside of the air lapping tube 50 and which have flexible extensions as 64 and 66. These flexible extensions 64 and 66 are designed of a length and flexibility such that they may be connected to an air supply tank 44 and can be drawn upwardly with the air lapping tube 50 when the cutter frame is raised by the plunger 38. At predetermined intervals in the upward travel of the air lapping tube, jets of air may be continuously released, being regulated by the valves 46 and 48. The air lapping tube is rigidly supported in the cutter frame by securing the conduit parts 56 and 58 in the base plate 34 as is illustrated in FIGS. 2 and 3.

In FIGS. 3 to 6 inclusive, there are illustrated progressive steps in carrying out the cutting and air lapping method of the invention. As shown therein, a span of extended web material (FIG. 4) is drawn from the roll 4 as a result of a finished roll R1 having been advanced onto the rolls 6 and 7, as was earlier described in reference to FIG. 1.

FIG. 4 illustrates the step of moving the cutter means upwardly towards the extended span of web W with the control valves having been simultaneously actuated to direct jets of air I upwardly against the underside of the core 8 and also against the underside of the uncut span of material. A suitable air pressure may, for example, be lbs. p.s.i.

FIG. 5 illustrates the cutting means coming into engagement with the web W and with the air jets progressively moving upwardly towards the underside of the core 8 as well as those portions of the web lying between the core 8 and the cutters.

In FIG. 6, there is illustrated the step of cutting the web to form a trailing end T and a free end P. As suggested diagrammatically in FIG. 6, the free end F has been forced upwardly and turned over on the core 8 into a position to carry out lapping. It will be observed that the traveling jets J have been progressively moved so as to be continuously in contact with the web portion being cut and to follow the cut portion. Thus there is realized a positive turning over of the cut end and a highly uniform lapping is carried out in a manner which prevents irregularity or wrinkling.

An important advantage inherent in the step of traveling the jets upwardly with the cutter frame is the adaptability of this combination of parts to deal with cores of varying sizes including, for example, cores of a diameter as little as one inch, running up to diameters of seven inches and more.

It will be apparent that by regulating the distance of travel of the plunger 38 relative to its cylinder 40, it is possible to provide for a sweeping action of the air jets over a distance sufficient to overlie cores of as large as seven inches diameter and greater, and no adjustment need be made other than control of the valves 41, 46 and 48.

It is pointed out that the combination of an air tank and time delay valve makes possible at the proper time supplying a high pressure, high velocity air blast. The higher air jet velocity thus realized will provide uniform wrinkle-free lap of the trailing edge. This is because of the relatively large volume of air being utilized for a short interval of, for example, approximately 3 seconds.

It will also be observed that the time delay insures that the air is released at a proper time depending on the web traveling time and the core size. The arrangement disclosed also provides that the supply tank is not exhausted too soon and air jet velocity decreased to a point where the air lap is ineffective before the cut occurs.

Other advantages realized are elimination of moving parts such as individually activated fingers, little if any maintenance required to keep the air lapping apparatus in good working condition,and savings in material and construction. There is no physical contact with the material other than by the cutter and the jets may be regulated to provide more uniform force in pushing the cut end around the core periphery. As the air jets rise into a position such as indicated in FIG. 6, it will be observed that they follow the cut end all the way around to the rear side of the core, thus insuring a positive lap ping action.

I claim:

1. A web winding machine for winding a web of material ontoa roll and cutting a stretched span of the web when the roll attains a desired size, said winding machine comprising a frame having jaws and a vertically adjustable core supported in the jaws, a rear driving roll for supporting and winding a partially formed roll of the material wound around the core, a forward driving roll located in the frame in substantially horizontally spaced relation to the rear driving roll for receiving a partially wound roll while supporting a stretched span of the web extending between itself and the rear driving roll, means for transferring the partially wound roll onto the forward driving roll at a predetermined point, core feeding apparatus for moving a replacement core onto the said jaws after the partially finished roll has been moved onto the forward driving roll, a vertically reciprocating web cutter mechanism mounted in the frame at points between the rear driving roll and the forward driving roll, said cutter mechanism being movable into contact with the underside of the said stretched span of material when the partially formed roll reaches a desired size, said web cutting mechanism including an elongated gate structure having spaced apart sides and cutter means mounted between the sides, means for vertically moving the gate and engaging the cutter means with the said span to sever the web and provide a trailing end and a free cut end of material, and air lapping means located in the gate structure below the cutter means and movable therewith for supplying travelling jets of compressed air arranged to be laterally directed against the first driving roll and which are mounted for progressive movement upwardly beneath said stretched span as said cutter means moves into a cutting position, and said travelling jets of compressed air being guided in a path of travel for 'movement against said cut end as cutting occurs to turn the cut end over onto the said winding core into overlapping relationship.

2. In a web winding machine in which'a web of material is wound around a supporting shell to form a web of a desired diameter and in which machine there is included a rear driving roll, a front driving roll, and means for moving a partially wound roll of material from one driving roll to the other, the combination of a gate mechanism for cutting the web of material while a portion thereof is supported in an extended position between the rear driving roll and the front driving roll, said gate mechanism including a frame having spaced apart sides, power driven chain cutter means mounted between the sides of the frame, fluid pressure actuated means for raising the frame and cutter means into cutting relationship with the extended portion of material to provide a free cut end of the web, air lapping means movable with the gate mechanism for directing travelling jets of air laterally inwardly and progressively upwardly against the said free cut end of the material, said air lapping means comprising an elongated tubular body rigidly secured between the said sides of the frame immediatelybelow the chain cutter means, conduit means for conducting compressed air into the tubular body and said tubular body being formed with apertures for releasing jets of air therefrom- Y 3. A web winding machine for winding a web of material onto aroll and cutting a stretched span of the web when the roll attains a desired size, said winding machine comprising a frame having jaws and a vertically adjustable core supported in the jaws, a rear driving roll for supporting and winding a partially formed roll of the material wound around the core, a forward driving roll located in the frame in substantially horizontally spaced relation to the rear driving roll for receiving and driving the partially wound roll while supporting a stretched span of the itself extending between iself and the rear driving roll, means for transferring the partially wound roll onto the forward driving roll at a predetermined point, core feeding apparatus for moving a re placement core onto the said jaws after the partially finished roll has been moved onto the forward driving roll, a vertically movable web cutter mechanism including an elongated gate structure having spaced apart sides and cutter means mounted between the sides, said gate structure being transversely disposed in the frame in front of and immediately below the said jaws for receiving a replacement core, means for supplying compressed air, a fluid pressure actuated device located in the base of the web winding machine and connected to the said gate structure, valve means for controlling flow of compressed air into the pressure actuated device and periodically moving the gate and cutter means upwardly into cutting engagement with the stretched span of material to provide a free cut endof material, said pressure actuated device being arranged to control movement of the gate and cutter means through a path of travel which locates portions of the gate above the said jaws and a replacement core therein, an air lapping apparatus for guiding the said cut free end of material around the replacement core, said air lapping apparatus comprising a tubular body solidly secured between the sides of the gate structure immediately below the cutter means and movable therewith, flexible conduit members connecting said tubular body with the means for supplying compressed air, said tubular body being core.

5. A structure according to claim 2 in which the fluid pressure actuated device includes a reciprocating piston of a length which in an extended position operates to raise the tubular body above the upper side of the core, and said valve means including independently operated control valves, including a time-delay valve for regulating operation of the air jets relative to operation of the compressed air actuated gate valve. 

1. A web winding machine for winding a web of material onto a roll and cutting a stretched span of the web when the roll attains a desired size, said winding machine comprising a frame having jaws and a vertically adjustable core supported in the jaws, a rear driving roll for supporting and winding a partially formed roll of the material wound around the core, a forward driving roll located in the frame in substantially horizontally spaced relation to the rear driving roll for receiving a partially wound roll while supporting a stretched span of the web extending between itself and the rear driving roll, means for transferring the partially wound roll onto the forward driving roll at a predetermined point, core feeding apparatus for moving a replacement core onto the said jaws after the partially finished roll has been moved onto the forward driving roll, a vertically reciprocating web cutter mechanism mounted in the frame at points between the rear driving roll and the forward driving roll, said cutter mechanism being movable into contact with the underside of the said stretched span of material when the partially formed roll reaches a desired size, said web cutting mechanism including an elongated gate structure having spaced apart sides and cutter means mounted between the sides, means for vertically moving the gate and engaging the cutter means with the said span to sever the web and provide a trailing end and a free cut end of material, and air lapping means located in the gate structure below the cutter means and movable therewith for supplying travelling jets of compressed air arranged to be laterally directed against the first driving roll and which are mounted for progressive movement upwardly beneath said stretched span as said cutter means moves into a cutting position, and said travelling jets of compressed air being guided in a path of travel for movement against said cut end as cutting occurs to turn the cut end over onto the said winding core into overlapping relationship.
 2. In a web winding machine in which a web of material is wound around a supporting shell to form a web of a desired diameter and in which machine there is included a rear driving roll, a front driving roll, and means for moving a partially wound roll of material from one driving roll to the other, the combination of a gate mechanism for cutting the web of material while a portion thereof is supported in an extended position between the rear driving roll and the front driving roll, said gate mechanism including a frame having spaced apart sides, power driven chain cutter means mounted between the sides of the frame, fluid pressure actuated means for raising the frame and cutter means into cutting relationship with the extended portion of material to provide a free cut end of the web, air lapping means movable with the gate mechanism for directing travelling jets of air Laterally inwardly and progressively upwardly against the said free cut end of the material, said air lapping means comprising an elongated tubular body rigidly secured between the said sides of the frame immediately below the chain cutter means, conduit means for conducting compressed air into the tubular body and said tubular body being formed with apertures for releasing jets of air therefrom.
 3. A web winding machine for winding a web of material onto a roll and cutting a stretched span of the web when the roll attains a desired size, said winding machine comprising a frame having jaws and a vertically adjustable core supported in the jaws, a rear driving roll for supporting and winding a partially formed roll of the material wound around the core, a forward driving roll located in the frame in substantially horizontally spaced relation to the rear driving roll for receiving and driving the partially wound roll while supporting a stretched span of the itself extending between iself and the rear driving roll, means for transferring the partially wound roll onto the forward driving roll at a predetermined point, core feeding apparatus for moving a replacement core onto the said jaws after the partially finished roll has been moved onto the forward driving roll, a vertically movable web cutter mechanism including an elongated gate structure having spaced apart sides and cutter means mounted between the sides, said gate structure being transversely disposed in the frame in front of and immediately below the said jaws for receiving a replacement core, means for supplying compressed air, a fluid pressure actuated device located in the base of the web winding machine and connected to the said gate structure, valve means for controlling flow of compressed air into the pressure actuated device and periodically moving the gate and cutter means upwardly into cutting engagement with the stretched span of material to provide a free cut end of material, said pressure actuated device being arranged to control movement of the gate and cutter means through a path of travel which locates portions of the gate above the said jaws and a replacement core therein, an air lapping apparatus for guiding the said cut free end of material around the replacement core, said air lapping apparatus comprising a tubular body solidly secured between the sides of the gate structure immediately below the cutter means and movable therewith, flexible conduit members connecting said tubular body with the means for supplying compressed air, said tubular body being formed along one side with a plurality of spaced apertures arranged to direct moving jets of air laterally to impinge on the core at points just below the cut free end of material, and thereafter to travel upwardly under the cut free end and lap the free end around the said core.
 4. A structure according to claim 2 in which the fluid pressure actuated device includes a reciprocating piston of a length which in an extended position operates to raise the tubular body above the upper side of the core.
 5. A structure according to claim 2 in which the fluid pressure actuated device includes a reciprocating piston of a length which in an extended position operates to raise the tubular body above the upper side of the core, and said valve means including independently operated control valves, including a time-delay valve for regulating operation of the air jets relative to operation of the compressed air actuated gate valve. 